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Objetivo

Several technological applications need tools for keeping a stable micrometric distance between two surfaces. The requirements are more stringent if electrical insulation has to be guaranteed between the surfaces and even more if also thermal insulation has to be satisfied.The dielectric microspacers (DMSs) here described represent a microtechnology able to meet all these requirements. DMSs were developed in the ProME3ThE2US2 FET project to separate two electrodes of an innovative high-temperature solar cell prototype. Since that device is part of the wider set of thermionic energy converters (TECs), DMS technology can be successfully applied to them, thus solving a technical problem only mitigated by palliative solutions during the last 50 years.The potentials connected to DMS technological innovation are scalability, robustness, high resolution, fabrication on large areas, thermal resistance and stability, very high electric and thermal resistivity, uniformity of physical properties, versatility of arrangement, and very accurate control of the separation gap.As mentioned, the immediate application is in TECs, initially for nuclear and aerospace applications and subsequently for allowing their introduction in the enormously increasing sector of industrial waste heat recovery. Application is expected also in fabrication of electronic devices. However, since new devices require effective and performing tools, in the same way as new tools open new perspectives for hi-tech devices, novel applications can be imagined. With this aim, DMS project starts with a critical study on possible complementary applications as well as on technical limitations and improvements. This activity will be preparatory for protecting the intellectual property in the widest possible application domain. A second phase will focus on technology transfer by qualifying and quantifying the possible market(s) and actors, aimed at defining an effective exploitation plan and promotion strategy.

"The Dielectric MicroSpacers (DMS) represent the key-enabling-technology (KET) to solve the technical problem of establishing fixed and stable physical gaps of few micrometres between two flat surfaces by ensuring electrical and thermal insulation. DMS technology is obtaining an important role in enhancing the efficiency of thermal-to-electric converters, especially the thermionic ones (TECs) where the historical limitation is in the lack of a technology able to establish a stable micrometric gap between the electrodes, causing a significant reduction of efficiency. DMS technology allows TECs working close to ideal conditions, with an increase of efficiency estimated to range from +50% to +250%, depending on the operating temperatures. This would boost TEC permeation in the sector of exhaust thermal energy recovery and would pave the route to application in other hi-tech sectors such as conversion of concentrated solar energy, transport, electronics, and ICT.

The importance of thermal-to-electric converters is exponentially growing in a modern society based on energy and to its efficient usage. A huge amount of thermal energy is lost in several manufacturing steps by industry, in transport vehicles, and also in domestic environments. DMS technology can be exploited in the medium-term for a capillary introduction of TECs in the huge sector of industrial heat recovery (petroleum and coal industry, chemical and primary metal manufacturing, etc.), corresponding to a market of 2 B€/year in US and EU. The applicative sectors of TECs are expanding also beyond heat recovery. Moreover, efficient TEC technology is going to enable a more efficient exploitation of concentrated solar energy and geothermic plants, thus inducing wider possibilities of application. All the described technologies and other applications such as electronics and automotive can receive benefits from DMS technical solution for a mature development and near-future commercialization.

The numbered objectives (O#) of the project were:O1) Expanding the potential of the technique by analyzing possible improvements.O2) Analyzing possible other technologies needing the application of DMS in order to enlarge the technological impact.O3) Protecting the technology by preparing and submitting at least one international patent application.O4) Analyzing the market and business opportunities on the basis of a document prepared by external business advisory services.O5) Drafting an exploitation plan for the technology.O6) Individuating and contacting possible stakeholders for a technology transfer."